Study on Tobacco Leave Lean Production Management System

In recent years, tobacco lean production infrastructure is almost full-fledged through development, and professional service scope expands accordingly. Hence, the developing emphasis has transformed from hardware facilities improvement to software updating of lean management and precise work. With related documents released by China Tobacco and Guizhou Tobacco, the achievement of comprehen- sive lean management probably becomes one of the key goals for the future devel- opment of tobacco business. The construction goal of tobacco leaves lean produc- tion management system is to internalize technology, information, human resources, material and other production elements into value stream of flue-cured tobacco pro- duction, and strict control value stream of input costs and output benefits, and then create management profit, promote enterprise, core competitiveness. The lean pro- duction management is both extension and expansion of modern tobacco agriculture, closely related to agricultural standardization and GAP management, which is based on professional service training and production machinery upgrading, with team management and station working as carriers, and information feedback, key quality monitoring and benefit evaluation as assessment references.

Lean Product Development Process with Design Verification Stages in the Value Stream of Automotive Industry

In the automotive industry, lean projects and innovation creation come to life by being updated under the control of systematic interdisciplinary process flows. The lean product development process that changes the shell, defined under the light of the variables created by the competitive conditions, is today measured by the value flow efficiency and the global market spread of the final product. Consequently, the lean product development approach, which aims to identify and purify all the wastes that do none value or create value to the system or cause burdens in the new product development process, is shaped by step-by-step approvals in the flow. In the main automotive industry company practices within the scope of the research (3 national, 3 international), the beginning of the concept of lean in design is to define and optimize the steps in the product development process under the value stream map. Therefore, the product function for which the customer has paid for, the function of the new product or the physical structure used to meet the needs in question, the comfort, life, experience, innovations of the scope that constitute the new product concept are planned and verified and implemented in the simplified automotive design stages at the beginning of the lean product development process. In this research, initial automotive design objectives and stages are at the focal point of the innovation and added value creation brought by the concept of “lean” approach. The research is modelled on the determination of steps that do not create added value together with the points where the flow circuits’ or stems, the process is devalued, the interdisciplinary holistic studies intensify, the information and delay begin and end in the sequential and simultaneous design validation step transition stages, which are examined under the lean approach. As a visual and virtual tool that enables the elaboration of nominal values such as the total duration of the design verification stages and the influence of interdisciplinary stakeholders or the test level of the product design with the new product added, it reveals the value flow or losses. Hence research;from innovation creation and new product design steps, which constitute the initial stages of the lean product development process, to design verification analysis, the efficiency of the automotive company processes within the scope of the research has been measured by comparing using lean automotive design techniques, methods and concepts.

Evaluation of Lean Product Development Stages of Autonomous Vehicle Technologies with AHP Method

The potential innovation and emerging workforce created by autonomous vehicle technologies, which have just entered the lean product development disciplines, play an important role in the development or change of the automotive manufacturing industry. Therefore, the intensity of work and the innovation practices brought by the technologies in question at each step of very different and interdisciplinary studies deeply affect the new and lean product development steps. Comparatively measuring the operating weight of new autonomous vehicle technologies in different company structures in these lean product development steps has important consequences for the development and change of the automotive industry under heavy global competition. On the other hand, it is difficult to measure the innovation input or the use of new autonomous technology under the AHP mathematical model of each part that constitutes the whole of the lean product development process, but it also creates the future predictions of the sector. The Analytical Hierarchy Process (AHP), which is one of the multi-purpose decision-making methods, was used to determine the most intense value creation, the design and development phase where there is innovation input, or the lean product development discipline throughout the whole process. The AHP method was preferred for the comparative analysis and synthesis of different applications or similar approaches in the automotive manufacturing industry companies (global and local) and lean product development processes in the field study of the research, under qualitative data. Under the AHP mathematical model created in the research, it was aimed to measure interdisciplinary clusters with a focus on new technology and to identify similarities or differences under alternative applications created by different company structures and to compare them systematically and evaluate them mathematically. In the study, the AHP mathematical model was used to compare lean product development processes and the use of new autonomous vehicle technologies, and the Expert Choice program was preferred in the application of the method.

Autonomous Vehicle Design in Lean Product Development Processes for Value Stream Map

The global automotive industry is giving a difficult and common test in order to create advanced life models in the near future plans or scenarios that include current autonomous vehicle technologies. Therefore, the main purpose of the research is to comparatively evaluate the impact of autonomous vehicle technologies, which are newly included in the automotive manufacturing industry under sustainable competition, on lean product development processes, value acquisition and preservation, in different organizational structures in the approach. Although mergers or brand acquisitions in the global automotive industry create joint R & D (Research Development) or joint new P & D (Product Development) process structures for the development of autonomous vehicle technologies, heavy competition continues in the market. These new processes create different needs for the merger and partnership of the renewed traffic infrastructures under national and international regulations, and for the implementation of the new autonomous life model. Firm and brand marriages, mergers or acquisitions in today’s automotive industry have ensured the high diffusion of lean product development processes under the stream of value creation or preservation carried out specific to the company under competition. Brand mergers in automotive industry companies struggling to survive under high competition create new work disciplines, professions, and engineering flow steps in lean product development processes. However, lean product development processes driven by technological innovation under simplification have resulted in the integration of parts and systems within the autonomous vehicle design structure, as well as creating new interdisciplinary value streams or different stakeholders. Therefore, the research revealed the significant effects of lean product development processes on the value stream in the automotive industry, on the mixed and lean product development process structure formed by new or existing vehicle systems (conventional vehicle) under the penetration of each existing and new discipline. This research compares the efficient operation steps of the process stakeholders in the autonomous vehicle design parts or systems containing innovation and new technology together with the value stream in the lean product development process, and the new process stakeholder’s business-oriented global and local automotive industry companies. New autonomous vehicle technologies, together with their unique software, hardware and development analysis, have been involved in the lean product development process with their interdisciplinary studies or expertise. Therefore, the study firstly focused on the technologies in environmental use together with the new basic features of autonomous vehicles, and then examined in depth the new or existing disciplines and interdisciplinary basic structure that these innovations affect under the value stream in the lean product development process. In addition, micro-level results and recommendations were shared, shedding light on how autonomous vehicle levels will create changes in the new product development process.

MONITORING CARBON EMISSIONS IN PRECAST CONCRETE INSTALLATION THROUGH LEAN PRODUCTION–A CASE STUDY IN SINGAPORE

The lean philosophy focuses on eliminating waste and maximizing productivity through the pull system,employee involvement,continuous improvement,etc.Much has been discussed about the waste elimination and productivity improvement that can be achieved by applying the lean concept.However,as the consideration of the environment is becoming an increasingly important part of the construction culture,there is a need to investigate the applicability of the lean concept to achieve environmental sustainability,which is often used interchangeably with the term“green”.This research therefore aims to investigate the contribution of the lean concept to achieve low-carbon installation in precast concrete construction sites through a case study in Singapore.The life cycle assessment(LCA)results show that the lean concept can be adopted to reduce carbon emissions in terms of eliminating waste and inappropriate erection arrangements.In the installation cycle of a specific type of precast concrete column,an amount of 20.9kg carbon emissions(71.0%)is caused by wastes and inappropriate erection arrangements and can be reduced by applying lean principles through a detailed simulation.Many lean management practices in site layout,delivery,stock and erection management are identified in this paper.Based on the results,contractors can start to apply lean principles to improve the installation cycle and eventually achieve low-carbon installation.

Exploiting Virtual Elasticity of Production Systems for Respecting OTD-Part 1: Post-Optimality Conditions for Ergodic Order Arrivals in Fixed Capacity Regimes

Respecting the on-time-delivery (OTD) for manufacturing orders is mandatory. This depends, however, on the probability distribution of incoming order rate. The case of non-equal distribution, such as aggregated arrivals, may compromise the observance of on-time supplies for some orders. The purpose of this paper is to evaluate the conditions of post-optimality for stochastic order rate governed production systems in order to observe OTD. Instead of a heuristic or a simulative exploration, a Cartesian-based approach is applied to developing the necessary and sufficient mathematical condition to solve the problem statement. The research result demonstrates that increasing speed of throughput reveals a latent capacity, which allows arrival orders above capacity limits to be backlog-buffered and rescheduled for OTD, exploiting the virtual manufacturing elasticity inherent to all production systems to increase OTD reliability of non JIT-based production systems.

Overview of the Theoretical Exploration and Application of Lean Six Sigma

In contemporary contexts,Lean Six Sigma(LSS)is extensively utilized and has evolved across various sectors due to its substantial benefits.This paper aims to explore the definition,origin,and development of LSS,as well as its key tools,methods,theoretical research,and future prospects.Furthermore,it analyzes the theoretical foundations and practical applications of LSS in-depth,with an emphasis on anticipating future development trends.The goal is to provide readers with a comprehensive overview of LSS and offer insights for enterprises seeking to implement LSS for process improvement and innovation.

Analysis of Waste in the Production of Concrete Blocks---A Case Study in the Goias Industry

An ever more demanding consumer market and the need for companies to be more competitive have led organizations to try to eliminate waste. This research is a case study which presents a proposal for intervention in order to improve performance of a pre-cast concrete block factory in outer Goihnia. As a first step, waste in the production process was identified through analysis of data on time involved in each step of the process. Then, applying the concepts of lean production, a list of activities was drawn up with a view to eliminating non-value-added work, identifying waste, decreasing cycle time, streamlining the production process and increasing the flexibility and transparency of the process. From the results, it was possible to identify the sources of waste and provide management with information for strategic decisions about production. Finally, various suggestions were made with a view to eliminating or mitigating bottlenecks in the production process.

Application of the Principles of Lean Thinking in the Post Construction Department

The increase on the competitiveness, the search on the customer satisfaction, the search by reducing waste in the civil construction were facts which helped entrepreneurs and companies to seek new ways of working, being lean construction one of the ways to get that. Studies report that the application of the lean tools in construction was carried out in an isolated way. This type of application was pointed as a major factor limiting the extent of achievement in implementing lean principles. The aim of this studies is to identify opportunities to implement the principles of lean production in the service department of a construction company in Goi^is, proposing routines that try to implement the continuous improvement of its processes, eliminating waste, reducing the lead time, allow it to perform the mapping processes, applying the just-in-time and among others, providing services that add value to the customer satisfaction. It was possible to establish the average time for each step, allowing to identify possible improvements in the department, from the perspective of lean principles. The research paper concludes by pointing out the activities for the Department of Post Construction work from building companies, from lean concepts.

USING LEAN PRACTICES TO IMPROVE CURRENT CARBON LABELLING SCHEMES FOR CONSTRUCTION MATERIALS-A GENERAL FRAMEWORK

The construction industry has considerable environmental impacts through the process of manufacturing building materials and building construction.Many environmental labelling programs have been introduced to the construction industry to measure the environmental impacts,including building up the environmental profiles for building materials.Although absolute measurements of the environmental impacts can be obtained by these labelling programs through detailed Life Cycle Assessment(LCA)studies,relative measurements should not be overlooked to indicate the gap between the current and the“leanest”performance.The term“lean”is often used to describe a process with less wastes,materials,human effort,time,etc.The lean concept originates from the Toyota Production System and has been applied in the automobile industry for decades.This paper therefore aims to investigate the applicability of a relative measurement of the environmental impacts for building materials by introducing the concept of“lean score”.The research aim is narrowed down by choosing the carbon labelling program and the precast concrete products as research objectives.The results indicate that a“lean”benchmark can be built to offer relative measurements of carbon emissions for precast concrete products.The lean score obtained from the benchmarking process provides the improving potential that can help the construction industry move towards sustainability.The results are also useful for regulatory bodies to establish national standards to measure the environmental impacts for building materials.

卡片导航平衡控制系统性能仿真研究

为了减少装配作业车间内因物料齐套产生的等待浪费,使具有装配约束的关联零件加工进度得到有效协同,设计一类卡片导航平衡控制系统(control of balance by card-based navigation,COBACABANA)。其基于两类卡片循环回路实现任务投放与作业分派的可视化进度协同控制逻辑。本文详细介绍系统的运行机制和系统控制参量,通过构建一般化的装配作业车间仿真模型,探讨在不同装配关联度下各控制参量的性能变化。实验结果表明,COBACABANA系统性能良好,并且选择合适的控制参量就能够有效提升关联零件的进度协同性。

智能制造背景下精益生产制造执行系统的应用

[目的]在智能制造中,制造执行系统(MES)面向生产线执行层,是信息化管理系统的核心组成部分。随着精益生产模式在轨道交通车辆制造业的快速推广,在提升产能的同时,也暴露出因制造资源管控松散、生产数据收集不便捷等因素产生的信息孤岛和信息断层所带来的问题,因此需对MES的应用情况进行分析。[方法]结合轨道交通车辆产品工位制节拍化生产组织模式,以及多品种、小批量离散制造等特征,基于结构化工艺设计和移动互联技术,搭建了基于精益生产工位制的MES。[结果及结论]通过构建生产要素三维立体关系,实现了结构化工艺设计输出驱动现场执行;以移动终端作业为引导,实现了生产透明化管理;对MES进行纵向横向拓展,通过对底层设备数据进行管理,实现了制造数据的互联互通。基于精益生产工位制MES的建设,实现了生产工艺可控、生产资源网格化、生产过程透明化的制造全过程动态管控。

数字化精益生产体系构建研究——基于某装配车间实例分析

从精益化、数字化到智能化,企业的转型和升级是企业维持长远、可持续发展的必要手段。在近10年中,国际产业格局重大调整,是中国制造业转型和革新的重要时机和窗口。目前,国内仍有许多企业停留在工业3.0或工业2.0向工业3.0的过渡状态,从上到下的发展步调不平衡、不一致,处于单项覆盖而难以系统集成的阶段,没有形成一个统一体系,导致存在信息传递不及时和数据分析不全面的问题。以某动车装配车间的建设为例,从产线规划、产线构建、运行管理和优化改进等4个方面,建立数字化车间的体系结构,实现从工位到产线再到车间的精益化和数字化融合,进一步推进企业从精益化到数字化再到智能化的转型。

Approaching lean product development using system dynamics:investigating front-load effects

Competing with successful products has become perplexing with several uncertainties and transmutes from time to time as customers＇ expectations are dynamic.That is why manufacturing firms exhaustively strive to look for a better competitive frontier using wellestablished and innovative product development（PD）processes.In this paper,we would like to answer three research questions：（i）What would be the effects of frontloading in PD？（ii）Can we improve our PD process endlessly？（iii）When is the critical time that the firm should take remedial action for improvements？As a contribution to the vast numbers of improvement methods in new product development（NPD）,this paper investigates the effects of front-loading using set-based concurrent engineering（SBCE）on cost and lead time.Models are developed and treated using a system dynamics（SD）approach.We assign a hypothetical upfront investment for SBCE and compare its effects on total cost and lead time of the development process.From the research,it is found that the total cost of PD is reduced almost by half-although the front loading is higher in order to encompass multiple design alternatives.The total product lead time is reduced by almost 20%.The model reveals the critical time for improvement of the PD process.We use SD tool（e.g.,STELLA）for simulation and visualization of the complex PD model,using SBCE as one of several strategies to frontload activities in the NPD process.

卷烟生产企业精益生产信息系统的设计与应用

本文从保障企业及品牌发展的战略高度,以大数据应用和信息化项目建设为支撑,系统研究了精益生产信息系统的设计原则、总体架构、建设目标、内容设计思路、系统建设、推广及应用,使精益管理理念得到普及,持续改善和追求卓越意识得以加强,管理水平持续提升,有效支撑企业核心品牌在更高水平上快速发展。

APS在封装基板智能工厂的设计与应用

文章重点探究先进计划及排配系统在封装基板工厂的设计和应用。鉴于封装基板生产工艺复杂,对生产计划与调度精度要求甚高。APS客制化系统设计综合考虑了封装基板工厂的工艺流程、设备特性和产能等要素,能依据订单需求、库存状况及生产能力,制定详尽灵活且有助于生产最大化的计划。其应用成效斐然,加快生产速度,极大提升资源配置效率,优化生产排程,缩短生产周期,降低生产成本。方法首先可通过需求与供给的匹配提供现有工单交期及投料计划,先以无限产能计算生产速度的权重值,再以有限产能设定各工站约束条件,实现连批生产,使产能最大化,最终实现长期产能规划模拟,提前评估人力、订单、物料及设备需求的变化。同时,通过实时监控和动态调整,增强应对生产不确定性的能力,大幅提高产品交付准时率,为封装基板工厂实现精益化生产、提升市场竞争力提供关键的技术支持与保障。

多品种小批量精益生产方式适应性分析

精益生产方式是在丰田生产方式基础上发展起来的一种强调彻底消除浪费、减低成本和持续改善的准时化生产方式。其目的是通过流程整体优化与持续改进,均衡物流,高效利用资源,最大限度消除浪费,降低成本,缩短周期,以最少的投入向顾客提供最完美价值的目的。

精益生产系统运作优化模型及求解方法

针对传统生产方式的不足和精益生产的要求,在分析精益生产系统运作的基础上,提出将精益生产的运作优化问题抽象为具体的大系统多目标规划问题。以车间制造元素的工作量作为决策变量,以产量、质量、成本、交货期等指标为动态约束条件构建优化运作模型。在模型中引入目标函数优先级及优先权因子,以反映多个相互矛盾目标的重要程度,可以根据实际问题的动态属性确定系统的最佳运作目标需求。为解决精益生产系统运作优化的动态性、多目标、多阶段性,给出一种采用'串式调优法'求解模型的算法。将精益生产系统运作优化模型简化为产能优化、时间优化以及平衡协调等子模型,应用'串式调优法'分别对子模型求解,结合浙江省某电能表装配生产线进行情况,将优化模型和求解算法通过Witness仿真验证,仿真结果表明了模型的合理性和求解算法的准确性、高效性。

精益造船——日本造船模式研究

通过对日本造船模式的研究,提出了精益造船模式,用有造船特征的精益生产理论,详细论述了造船生产过程中的精益生产方法,介绍了一种可供我国造船企业借鉴的现代造船模式.

上湾煤矿精益化管理体系构建及其应用效果

针对上湾煤矿持续多年的高位运行状态和严峻的国内外煤炭市场形势,通过分析制造执行系统中的数据和麦肯锡对神东集团与上湾煤矿的诊断结论,结合自身实际,提出了上湾煤矿精益化管理体系的基本内涵与实施思路。在此基础上,通过培养典型精益文化、优化生产现场作业流程、引入国际通用的关键绩效指标、运用经济适用新技术等主要手段,使得上湾煤矿2012年与2010年相比,综、连采效率得到提升,综采设备综合运行效率和产能分别提升8.51%和10.5%,连采实际作业生产时间增加582h;成本得到有效控制,吨煤电耗降低了0.22元;用工人数得到降低,车队定编人员减少了108人,排水人员减少86人。